TOYOTA COROLLA VERSO 2004 Service Repair Manual

A38025
SST 1 ± A
A38126
A38105
19±30
± STARTING & CHARGINGGENERATOR ASSY(90A) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Mount SST 2 in a vise.
(d) Insert SST 1 ± A, B into SST 2, and attach the pulley nut
to SST 2.
(e) Tighten the pulley nut, turn SST 1 ± A in the direction
shown in the illustration.
Torque: 111 N
m (1,125 kgf
cm, 81 ft
lbf)
(f) Remove the alternator form SST 2.
(g) Turn SST 1 ± B, and remove SST 1 ± A, B.
(h) Turn the pulley, and check that the pulley moves smooth-
ly.

190AI±01
A62720
Drive End Frame Assy Generator w/ Clutch Pulley
Alternator Pulley CapGenerator Rotor Assy
Rear End Cover
Sub±Assy Rear Seal Plate
Generator Brush
Holder Assy
Front Seal
Plate
Alternator Coil Assy
N´m (kgf´cm, ft´lbf)
: Specified torque
5.8 (59, 51 in.´lbf)
1.8 (18, 16 in.´lbf)
4.6 (47, 41 in.´lbf)
± STARTING & CHARGINGGENERATOR ASSY(130A) (1CD±FTV)
19±31
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
GENERATOR ASSY(130A) (1CD±FTV)
COMPONENTS

190AJ±01
A55648
A55649
A55650
SST (A)
SST (B)
A55651
Rotor Shaft
SST (A)
19±32
± STARTING & CHARGINGGENERATOR ASSY(130A) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. REMOVE GENERATOR BRUSH HOLDER ASSY
(a) Remove the 3 nuts and rear end cover.
(b) Remove the B terminal insulator.
(c) Remove the rear plate seal from the brush holder.
(d) Remove the 2 screws and brush holder.
(e) Remove the front seal plate from the rear frame.
2. REMOVE GENERATOR W/CLUTCH PULLEY
(a) Set SST (A) and (B).
SST 09820±63020
(b) Mount SST (A) in a vise.
(c) Set the alternator to SST.
NOTICE:
At this time, make sure that the alternator and SST are per-
pendicular to one another.

A57794
SST (B)
Turn
A57795
A57796
SST
A57797
A57798
± STARTING & CHARGINGGENERATOR ASSY(130A) (1CD±FTV)
19±33
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(d) Insert the 3 tabs of SST (B) into the 3 holes on the pulley.
(e) To loosen the pulley, turn SST (B) in the direction shown
in the illustration.
(f) Remove the alternator from SST.
(g) Remove the pulley from the rotor shaft.
3. REMOVE GENERATOR ROTOR ASSY
(a) Remove the 4 through bolts.
(b) Using SST, remove the coil assembly.
SST 09950±40011 (09951±04020, 09952±04010,
09953±04020, 09954±04010, 09955±04071,
09958±04011)
(c) Remove the alternator washer.
(d) Remove the rotor from the drive end frame.
4. INSPECT GENERATOR ROTOR ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Standard resistance: 2.3 ± 2.7
at 20
C (68
F)
(b) Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.

A57799
A57800
A57801
A57802
Socket
Wrench
(29 mm)
A57795
19±34
± STARTING & CHARGINGGENERATOR ASSY(130A) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Check that the slip rings are not rough or scored.
(d) Using vernier calipers, measure the slip ring diameter.
Standard diameter:
14.2 ± 14.4 mm (0.5591 ± 05669 in.)
Minimum diameter: 14.0 mm (0.551 in.)
5. INSPECT GENERATOR BRUSH HOLDER ASSY
(a) Using vernier calipers, measure the exposed brush
length.
Standard exposed length: 10.5 mm (0.4134 in.)
Minimum exposed length: 4.5 mm (0.177 in.)
HINT:
If the exposed length is less than minimum, replace the brush
holder.
6. INSTALL GENERATOR ROTOR ASSY
(a) Place the drive end frame.
(b) Install the rotor to the drive end frame.
(c) Place the alternator washer on the rear bearing.
(d) Using a socket wrench (29 mm)and press, slowly press
in the coil assembly.
(e) Install the 4 through bolts.
Torque: 5.8 N
m (59 kgf
cm, 51in.
lbf)

A55650
SST (A)
SST (B)
A55651
Rotor Shaft
SST (A)
A57803
SST (B)
Turn
A57804
Upward
A55648
± STARTING & CHARGINGGENERATOR ASSY(130A) (1CD±FTV)
19±35
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
7. INSTALL GENERATOR W/CLUTCH PULLEY
(a) Temporarily install the pulley to the rotor shaft.
(b) Set SST (A) and (B).
SST 09820±63020
(c) Mount SST (A) in a vise.
(d) Set the alternator to SST.
NOTICE:
At this time, make sure that the alternator and SST are per-
pendicular to one another.
(e) Insert the 3 tabs of SST (B) into the 3 holes on the pulley.
(f) To torque the pulley, turn SST (B) in the direction shown
in the illustration.
Torque: 111 N
m (1132 kgf
cm, 82 ft
lbf) for using SST
HINT:
Use a torque wrench with a fulcrum length of 50 cm (19.69 in.).
(g) Remove the alternator from SST.
(h) Install a new alternator pulley cap.
8. INSTALL GENERATOR BRUSH HOLDER ASSY
(a) Place the front seal plate to the coil assembly.
(b) Install the brush holder with the 2 screws.
Torque: 1.8 N
m (18 kgf
cm, 16 in.
lbf)
NOTICE:
Be careful of the holder installation direction.
(c) Place the plate seal on the brush holder.
(d) Install the rear end cover with the 3 nuts.
Torque: 4.6 N
m (47 kgf
cm, 41 in.
lbf)